Electrical discharge Machining:

Principle:

Electrical discharge machining process works on the basic principle of spark generation and
metal removed by spark erosion. EDM spark erosion is same as electric spark which burn a
small hole in a piece of metal through witch it contacts. The spark generated by this process
produces heat, which remove metal by erosion and evaporation. In this machining process
both the work piece and tool must be made by conductive material.

Equipment’s : Power Supply: In a EDM process a high frequency current used to

generate spark between electrode and work piece. This spark generates heat and
remove metal form work piece.

Dielectric fluid supply and flushing system:The dielectric fluid acts as a vehicle to drive
away the chips and thus preventing them from sticking to the surface. This fluid acts
as flushing system for chips. It also helps in increasing the metal removal rate by
promoting spark between tool and work. This fluid also works as coolant medium.

Tool and tool holding devices

Work piece and work holding devices

Working

 First both work piece and tool are submerged into dielectric fluid. The dielectric fluid help to
control the arc discharge. This also removes suspended particles of work piece material and tool
from the work cavity.
 A servomechanism is used which maintains a very small gap between the work piece and the tool.
This gap is desirable for proper arc formation. It is about the thickness of human hair.
 The tool is made as the opposite shape of work piece.
 A high frequency current supplied to electrode, which produces a spark between the tool and
work piece. This spark generates high in work cavity.
 The metal removed from the work piece due to erosion and evaporate ion.
 The chips or suspended particle between tool and work piece should be removed to prevent
them to form bridge that causes short circuit. This is done by continuous supply of dielectric fluid.
 The EDM produce a cavity slightly larger than the electrode because of overcut.

Advantages:

 Every conductive material can be cut by this process.

 It is independent on hardness of workpiece so hardened work piece can be
machined easily.
 Complex die section and complex shapes can be produce accurately.
 This process is burr free.
 Thin section can be easily machined without deforming the part.
Disadvantages:

 In this machining process high tool wear occurs.

 Tool wears limits accuracy and surface finish of metal.
 Only good conductors of electricity can be machined by EDM.
Electrochemical Machining (ECM):

Principle of Electrochemical Machining:

Electrochemical machining works on the Faraday law of electrolysis which state that if two
electrode are placed in a container which is filled with a conductive liquid or electrolyte and
high ampere DC voltage applied across them, metal can be depleted form the anode
(Positive terminal) and plated on the cathode (Negative terminal). This is the basic principle
of electrochemical machining.

In this machining process, tool is connected with the negative terminal of battery (work as
cathode) and work-piece is connected with the positive terminal of battery (work as anode).

They both are placed in a electrolyte solution with a small distance. When the DC current
supplied to the electrode, metal removed from work-piece. This is basic fundamental of
electrochemical machining.
Working of Electrochemical Machining:

Electrochemical machining works inverse as electroplating process. Metal is removed form anode into
electrolyte and convert into slag form by reacting opposite ions available in electrolyte. This process
works as follow.

 In ECM, the electrolyte is so chosen that there is no plating on tool and shape of tool
remain unchanged. Generally NaCl into water takes as electrolyte.
 The tool is connected to negative terminal and work is connected to positive
terminal.
 When the current passes through electrode, reaction occur at anode or workpiece
and at the cathode or tool.
 Due to potential difference ionic dissociation take place in electrolyte.
NaCl ↔ Na+ + Cl-
H2O ↔ H+ + OH-
 When the potential difference applied between the work piece and tool, positive ions
move towards the tool and negative ions towards the work piece.
 Thus the hydrogen ion moves towards tool. As the hydrogen reaches to the tool, it
takes some electron from it and converts into gas form. This gas goes into
environment.
 When the hydrogen ions take electron from tool, it creates lack of electron in
mixture. To compensate it, a ferrous ions created at the work piece (anode) which
gives equal amount of electron in mixture.
2H+ + 2e- = H2 ↑ at Cathode
Fe = Fe+ + + 2e- at Anode

 These Ferrous ions react with opposite chlorine ions or hydroxyl ions and get
precipitate in form of sludge.
Iron (Fe) ↔ Fe++ + 2e-
Fe++ + 2Cl- ↔ FeCl2
Fe++ + 2(OH)- ↔ Fe(OH)
Fecl2 + 2(OH)- ↔ Fe(OH)2 + 2Cl

 This will give ferrous or iron into electrolyte and complete the machining process.
This machining process gives higher surface finish because machining is done atom
by atom.

Application:

 ECM is used to machining disk or turbine rotor blade.

  It can be used for slotting very thin walled collets.
 ECM can be used to generate internal profile of internal cam.
 Production of satellite rings and connecting rod, machining of gears and long profile
etc.
Advantages and Disadvantages:

Advantages:

 It can machine very complicated surface.

 A single tool can be used to machining large number of work-piece. Theoretically no
tool wear occur.
 Machining of metal is independent on strength and hardness of tool.
 ECM gives very high surface finish.
Disadvantages:

 High initial cost of machine.

 Design and tooling system is complex.
 Fatigue property of machined surface may reduce.
 Nonconductive material cannot be machined.
 Blind hole cannot be machined form ECM.
 Space and floor area requirement is high compare to conventional machining.
Ultrasonic Machining:

Principle:

It works on the same principle of ultrasonic welding. This machining uses ultrasonic waves
to produce high frequency force of low amplitude, which act as driving force of abrasive.
Ultrasonic machine generates high frequency vibrating wave of frequency about 20000 to
30000 Hz and amplitude about 25-50 micron. This high frequency vibration transfer to
abrasive particle contains in abrasive slurry. This leads indentation of abrasive particle to
brittle work piece and removes metal from the contact surface.

EQUIPMENT

POWER SOURCE

Magnetostrictive transducer: a device which converts electric single into mechanical

vibration. In ultrasonic machining magnetostrictive type transducer is used to
generate mechanical vibration. This transducer is made by nickel or nickel alloy.
Booster:The mechanical vibration generated by transducer is passes through booster
which amplify it and supply to the horn.

Tool:The tool used in ultrasonic machining should be such that indentation by abrasive
particle, does not leads to brittle fracture of it. Thus the tool is made by tough, strong
and ductile materials like steel, stainless steel etc.

Tool holder or Horn:As the name implies this unit connects the tool to the transducer. It
transfers amplified vibration from booster to the tool. It should have high endurance
limit.

Abrasive Slurry:A water based slurry of abrasive particle used as abrasive slurry in
ultrasonic machining. Silicon carbide, aluminum oxide, boron carbide are used as
abrasive particle in this slurry. A slurry delivery and return mechanism is also used in
USM.

Working process:

 First the low frequency electric current passes through electric supply. This low
frequency current converts into high frequency current through some electrical
equipment.

 This high frequency current passes through transducer. The transducer converts this
high frequency electric single into high frequency mechanical vibration.
 This mechanical vibration passes through booster. The booster amplify this high
frequency vibration and send to horn.
 Horn which is also known as tool holder, transfer this amplified vibration to tool
which makes tool vibrate at ultrasonic frequency.
 As the tool vibrates, it makes abrasive particle to vibrate at this high frequency. This
abrasive particle strikes to the work piece and remove metal form it.
Application:

 This machining is used to machine hard and brittle material like carbide, ceramic,
glass etc.
 This is used in machining of die and tool of drill, wire drawing machine etc.
 Used in fabrication of silicon nitrite turbine blade.
 It is used to cut diamond in desire shape.
 It is used machining of machining non-conductive hard material which cannot be
machined by ECM or EDM due to poor conductivity.
Advantages:

 Hard material can be easily machined by this method.

 No heat generated in work so there is no problem of work hardening or change in
structure of work piece.
 Non-conductive metals or non-metals, which cannot be machined by ECM of EDM
can be machined by it.
 It does not form chips of significant size.

Disadvantages:

 It is quite slower than other mechanical process.

 Tool wear is high because abrasive particle affect both work-piece and tool.
 It can machine only hard material. Ductile metal cannot be machine by this method.
 It cannot used to drill deep hole.
Abrasive Jet Machining:
Principle:

This machining process works on the basic principle of abrasive erosion. If a high velocity
abrasive particles strike on a hard or brittle work piece, it remove some metal at the striking
surface. This metal removal process takes place due to brittle fracture of metal and also due to
micro cutting by abrasive particle. This is principle process of abrasive jet machining.

Equipment’s:

Gas Propulsion System: The main purpose of gas propulsion system is to provide clean and dry,
high velocity air or gas for machining. Mostly air, carbon dioxide, Nitrogen etc. are used as gas in
gas propulsion system. This system consists, compressor, air filter and drier.

Abrasive feeder:As the name implies, abrasive feeder is used to provide abrasive particles in
mixing chamber. It is fed through a sieve which vibrates at 50-60 Hz and mixing ratio is control by
the vibration of the sieve and its amplitude.

Abrasive: The most common abrasive particles used are aluminum oxide, silicon carbide, boron
carbide etc. The selection of abrasive particle is depends upon material of work piece, speed of
machining, and machining environment.

Cutting Nozzle:To direct the abrasive particle on work piece cutting nozzles are used. They are
usually made by tungsten carbide.
Machining Chamber:It is fully closed air tight chamber witch control the concentration of
abrasive particle around work piece. This is equipped with a vacuum dust collector which collect
used abrasive particle and removed material from mixing chamber.

Working:

 First gas or air is compressed into gas compressor. There the density and pressure of
gas increases.
 This clean gas sends to drier, which absorb moisture from it. It is used to avoid water
or oil contamination of abrasive power.
 Now this clean and dry gas sends to mixing chamber where abrasive feeder feed
abrasive particle in it. The abrasive particle is about 50 micro meter grit size.
 This high pressuring abrasive carried gas send to nozzle where its pressure energy
converted into kinetic energy. The velocity of abrasive particle leaving the nozzle is
about 200m/s.

The standoff distance between work piece and nozzle is about 2mm.
 Now these high velocity abrasive particles impinge on work piece. These high
velocity abrasive particles remove the material by micro cutting action as well as
brittle fracture of the work material.
Application:

 It is used in drilling and cutting of hardened metals.

 It is used for machining brittle and heat sensitive material like glass, quartz, sapphire,
mica, ceramic etc.
 It is Use to manufacture electronic devices.
 It is used in deburring small holes and some critical zones in machine parts.
Advantages:

 High surface finish.

 It can machine heat sensitive material.
 It is free from vibration
 Initialization cost is low compare to other non-traditional processes.
 Thin section can be machined easily.

Disadvantages

 Low metal removal rate.

 Abrasive particle can embedded into work piece mostly in soft metals.
 Nozzle life is limited so it needs frequently replacement.
 Abrasive particle cannot be reuse in this process.
 It cannot use for machine soft and ductile material.
Laser Beam Machining
Working Principle of Laser Beam
Machining:
 A very high-energy laser beam is produced by laser machines.
 Focuses on the workpiece to mechanize this laser beam produced.
 When the laser beam hits the surfaces of the W/P, the thermal energy of
the laser beam is transferred to the surfaces of the W/P.
 It heats, melts, evaporates, and eventually makes the material a
workpiece.
 This is how laser beam machining works.
 It works on the principle that when a high-energy laser beam strikes the
surfaces of the workpiece.
 The heat energy contained by the laser beams is transferred to the surface
of the w/p.
 This heat energy absorbed by surface heat melts and evaporates the
material w/p. Machining of materials in this way is done using laser beams.
Application:

 Used to drill small hole of diameter about 0.005 mm in refectory and ceramic
materials.
 It is used in drilling and cutting for both metals and non-metals.
 It is extensively used in electronic and automotive industries
 It is mostly used in aerospace industries.
 Used to machine complex profile where machining by tool is not possible.
Advantages:

 It can cut all material.

 No tooling cost because no physical tool is required.
 It produces finish part or high surface finish.
 No tool wear because no physical tool is used.
 Micro holes can be drilled accurately.
 Complex shape can be machined easily because laser can be move in any path.
 Very hard material can be cut through laser beam machining.
 High accuracy can be achieved.
 It can be easily automated and flexible.
Disadvantages:

 It is uneconomical when high volume of same shape to be cut compare to stamping.

 High capital and maintenance cost.
 It cannot use to produce blind hole.
 Laser can leads to safety hazards.
Electron Beam Machining:
Principle:

This machining process works on basic principle of conversion of kinetic energy of electron
into heat energy. When a high speed electron impinges on a work piece, they convert its
kinetic energy into heat energy. This heat energy used to vaporize material at contact
surface. This process is carried out in vacuum otherwise the electron will collide with air
particle and loses its energy before impinging on work material. This is basic principle of
EBM machining.

Working:

 First electron gun produces high velocity electron particles. These electron particles
move towards anode which is placed after cathode tube.
 Now this high intense electron beam passes through magnetic lenses. There are a
series of lenses which take care of only convergent electron passes through it. It
absorb all divergent electron and low energy electron. It provides a high quality
electron beam.
 This electron beam now passes through electromagnetic lens and deflecting coil. It
focus the electron beam at a spot.
  The high intense electron beam impinges on the work piece where kinetic energy of
electrons convert into thermal energy.
 The material is removed from contact surface by melting and vaporization due to this
high heat generated by conversion of kinetic energy into thermal energy. This whole
process take place in a vacuum chamber otherwise these electron collide with air
particle between path and loses its kinetic energy.
Application:

 It is used to produce very small size hole about 100 micro meters to 2 millimeter.
 It is used to produce holes in diesel injection nozzle.
 Used in aerospace industries for producing turbine blade for supersonic engines and
in nuclear reactors.
Advantages:

 It can be used for produce very small size hole in any shape
 It can machining any material irrespective its hardness and other mechanical
properties.
 It provides good surface finish. No any surface finishing process is require after EBM.
 Highly reacting material can be machine easily because machining is done under
vacuum.
Disadvantages:

 High capital cost.

 High skill operator required.
 Low material removal rate.
 Regular maintenance is required
 Material removal rate is very low compare to other conventional process.
 It is difficult to produce perfect vacuum.

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